Packaging of self-dischargeable wire



Nov. 3, 1970 w. J. GILMORE: Erm. 3,537,252

PACKAGING 0F SELF-DISQHARGEABLE WIRE original Filed sept. s, 196s v 3 Sheets-Sheet 2 Nov. 3, 19.7 0

W. J. GILMORE ETAL PACKAGING OF .SELF-DISCHARGEABLE WIRE 3 sheis-sheet 1 Original Filed Sept.

INVENTORS WILLIAM J. GILMORE VINCENT C.J. PETERSON Tana-v ATTgRNEYS W. J. GII-.MORE ET AL PACKAGING OF SELF-DISCHARGEABLE WIRE Nov. 3, 197.0

3 Sheets-Sheet 5 Original Filed Sept. 5, 1963 N Mo SOS s RMR Y OLV. E TmE N N P R EJ. m WAMHC IT Mm WC N.. Ml V United States Patent Office 3,537,252 Patented Nov. 3, 1970 Application Sept. 5, 1963, Ser. No. 307,284, now Patent No. 3,465,743, which is a continuation-in-part of application Ser. No. 274,896, Apr. 17, 1963, which in turn is a continuation-in-part of application Ser. No. 203,979, June 20, 1962. Divided and this application Dec. 2, 1968, Ser. No. 799,537

Int. Cl. F41b 7/02; B65h 54/00 U.S. Cl. 57-156 Claims ABSTRACT F THE DISCLOSURE The method of making a package of self-dischargeable wire by twisting the wire longitudinally, rendering the twisting resiliently permanent and helically wrapping the twisted wire under tension into a multiple layered cylindrical winding.

This application is a divisional of our copending application Ser. No. 307,284, tiled Sept. 5, 1963, now U.S. Pat. No. 3,465,743, Sept. 9, 1969. Application Ser. No. 307,284 is a continuation-in-part of our prior application Ser. No. 274,896, filed Apr. 17, 1963, now abandoned, which is in turn a continuation-in-part of our application Ser. No. 203,979, filed June 20, 196,2, now abandoned.

This invention relates to both a product and a method in the art of packaging self-dischargable wire. The product of the invention relates in particular to a helically wrapped package of at wire capable of forcibly twisting longitudinally throughout its length so that when desired it can hurl itself rapidly outwardly under the cumulative impulse of its own released elastic energy. The method of the invention relates in particular to passing a at wire between spaced pairs of rolls, one of which is revolved to twist the section of wire between the pairs of rolls longitudinally, then rendering the twist resiliently permanent, and finally helically wrapping the twisted wire under tension at about a core,

The chief purpose of this invention is the provision of a helically wrapped coil or package of flat wire in which is stored suicient energy to permit the wire to unwind itself and discharge linearly outwardly with considerable force until virtually the full length has been payed out. This characteristic renders the new package of substantial advantage for a wide range of uses which will be fully apparent from the following detailed description. It can serve wherever a line must be thrown out between spaced points; for example where a heave line is to be cast from a ship, where a cable is to be drawn through an extended conduit, or where a wire rope is to span a body of water at the start of a bridge-building operation. The new ilat wire package can discharge itself between the spaced points and'then the cable or rope can be hauled across by the flat wire.

In this process of self-propulsion, the flat wire arches out coaxially from the center of the package and if its generally linear travel is interrupted by an obstruction it will pile up into an entangled mass. Hence, the package can also be used to erect a barrier not unlike a barbed wire emplacement.

The at cross section of the wire in this package is an improved feature of primary importance in the new product because the invention requires that as the wire discharges it should exhibit an elastic change in shape whereby the cylindrical configuration of each successive convolution rotates into a longitudinally twisted configuration about an axis coincident with the center line of the wire so that the faces of the wire define helical surfaces. This is a notable advantage over round Wire particularly when the package is to be used to form an entangled obstacle similar to a barbed wire emplacement. A sharp knife edge or series of barb-like serrations can easily be formed continuously along one or both edges of a flat wire, whereas with a round wire it is far more ditiicult if not practically impossible. Once such serrations are formed on a at wire they too can lie flat in the wound coil without hooking onto adjacent turns, whereas hooks or barbs attached to a round section will catch onto adjacent turns and pull snarls of wire from the package during discharge. In addition resilient spaced barbs may be located along the opposed faces of two or more strips superimposed one over the other to constitute a laminated form of the at wire, and still avoid snarling during the wrapping and discharging operations.

Broadly stated, the new package of self-dischargeable wire comprises an extended length of at wire helically wrapped into a multilayered cylindrical Winding with a plurality of helical turns in each layer. This winding is preferably formed about a collapsible core. The at wire in the winding is characterized in that it is possessed of considerable stored elastic energy tending forcibly to produce a longitudinal twist in the wire about an axis extending therewithin so that the surfaces of wire define helical surfaces. Restraining means are provided for holding the winding in its cylindrical form and containing the stored elastic energy in the at wire. Means are also included for selectively disabling at least part of the restraining means (for example, means for collapsing the collapsible core) to permit the flat wire forcibly to produce the above-mentioned twist in itself progressively from one end to the other. When thus freed, the flat wire hurls itself rapidly outwardly under the cumulative impulse of its own released energy.

Because of the elastically suppressed resiliently permanent helical twist in the flat wire Within the package, and also because the wire is flat-wrapped into a multilayered cylindrical winding with a plurality of helical turns in each layer, this progressive release of the flat wires stored elastic energy from one end to the other causes it to fly almost instantaneously from the package at typical speeds of about forty miles per hour through a distance of perhaps eighty feet or more. It is surprising, and quite advantageous, that in this rapid self-discharge the at wire runs out from the package in a markedly linear manner, not unlike a stream of water, but if its linear progress is interrupted it will build up at that point into an entangled mass.

It has been known heretofore to provide packages of wire which may be released of contained elastic energy to form something of an entangled mass, but the wire in such packages is spirally wound and tends to unwind spirally in the manner of a clock spring. No such prior art device has been capable of anything like the degree of cumulative released energy characteristic of the product of this invention, nor can they discharge their wire linearly outwardly between widely spaced points in any manner similar to the progressive cumulative propulsion of wire characteristic of the present package.

In accordance with the invention, the new package may also include a unique laminated form of the flat wire which is helically wrapped into the multi-layered cylindrical winding. Such a at wire comprises at least first and second at strips separably superimposed compressively together in the winding. A plurality of elements on at least this irst strip are resiliently flattened by the second strip in the winding and'tend to spring outwardly from the first strip. In a specific form of this embodiment, the plurality of elements may be spaced longitudinally along the wire with alternate elements attached to the respective first and second strips, so that each element tends to spring outwardly from the strip to which it is attached toward the opposite strip. Each element may further be pointed at its outer end and barbed along its edges.

The method of the invention for making a package of self-dischargeable flat wire broadly comprises the following sequence of steps. A flat wire is passed between a first pair of opposed rolls and then between at least one other pair of opposed rolls spaced from the first pair. This other pair of opposed rolls is revolved a predetermined number of revolutions with respect to the first pair, thereby imparting a longitudinally twisted configuration to the section of the at wire between the pairs of rolls about an axis extending within the wire so that the faces of the wire define helical surfaces. The revolved pair of opposed rolls is then secured against further revolution, and the twisted configuration in the section of the flat wire between the pairs of rolls is rendered resiliently permanent. Thereafter, the wire is forcibly withdrawn from the abovementioned other pair of rolls and at the same time restrained from returning fully to its resiliently permanent configuration. Finally, the withdrawn flat wire is helically wrapped underapplied .tension about a rotatable nonrevolvable core to form a multilayered cylindrical winding with a plurality of helical turns in each layer.

Wherever the term revolvable or variations thereof is used in the following description and claims, it is intended to distinguish from the term rotatable or variations thereof. Inl its present usage, rotatable means that a member turns about an axis (usually its longest axis of symmetry) inthe manner of a shaft, whereas revolvable means that that axis of rotation of the member turns end-over-end in the manner of a twirling baton. Also, the term .flat wire as used herein has reference to its fiat cross section, whether such wire is longitudinally flat or longitudinally twisted, orwhether of a single strip or laminated construction, unless otherwise noted.

It is not unknown to impart a resiliently permanent longitudinal twist to a fiat wire which is somewhat similar in general configuration to that effected in the abovedescribed method of the invention. However, this has never been done to prepare the wire for later storage of considerable elastic energy. It also is not unknown to package such conventional twisted at wire by winding it into a spirally-wrapped pancake-type coil about an ordinary rigid core. However, these practices have absolutely nothing to do with a method of making a helically wrapped package of flat wire capable of forcibly twisting longitudinally throughout its length so that it can hurl v vitself rapidly outwardly under the cumulative impulse of its own released energy. Thus, the new method is neither evolved from nor does it share any related mode of operation with those known spirally-wrapped pancake-type coils of flat wire which may twist with inconsequential force into a helical configuration after being payed off their reel by some exterior force in a conventional manner. To

the best of our knowledge, it has never been thought of heretofore to store energy in a fiat wire package by flatwrapping in a helical form an otherwise permanently twisted at wire in accordance with the method of this invention. And, of course, the art hasl Ibeen even less aware that as a result of such method of storing elastic energy in a package it is possible to produce a device of the new type which is capable of hurling its flat wire outwardly at great speed and through a considerable distance under the cumulative impulse of its own released energy.

Preferred embodiments of the invention are described hereinbelow with reference to the accompanying drawings wherein FIG. 1 is an enlarged fragmentary section of a barbededge flat wire of one type suitable for the new package;

FIG. 2 is a schematic illustration, not in scale, showing one` sequence of steps to be followed in the practice of the new method;

FIG. 3 is an illustration of the new package discharging its wire in use;

FIG. 4 is a schematic illustration, also not in scale, showing another sequence of steps to be followed in carrying out the method of invention;

FIG. 5 is a schematic illustration, also not in scale, showing a sequence of steps similar to those of FIG. l to be followed in making a different embodiment of the new package wherein two superimposed strips form the flat wlre;

FIG. 6 is an enlarged fragmentary perspective of one resiliently barbed strip used in carrying out the method of FIG. 5;

FIG. 7 is a longitudinal section, distorted somewhat for purposes of clarity, of the FIG. 6 strips superimposed into a flat wire in accordance with the FIG. 5 method;

FIG. 8 is a view similar to FIG. 6 showing another form of the resiliently barbed strip;

FIG. 9 is another view similar to FIG. 6 showing a further form of the resiliently barbed strip; and

FIG. 10 is a schematic illustration, not in scale, showing another sequence of strips to be followed in the practice of the new method.

A flat wire 10 is required for the new package. It may advantageously be of high-carbon spring steel, perhaps about one quarter of an inch wide and cut from .02.5 inch thick rolled stock. As shown in FIG. 1, a serrated cutting edge 11 may be provided along one longitudinal side of the at wire 10 when the package is to form a kind of barbed-wire barrier or obstacle. As noted previously, this is a feature which cannot for all practical purposes be present if round wire is used in the package because a knife edge or integral barbs cannot readily be formed along a length of round wire. Also, any separate barbs or hooks attached to a round wire could not lie flat in a coil, as the serrations 11 on the fiat wire 10' can, and would hook onto adjacent turns during discharge to snarl the round wire completely.

Referring to FIG. 2, the method lof the invention can be carried out in one of its more basic forms by initially passing one end of an indefinite length of the flat wire 10, into a quenched and tempered condition, through a first pair of opposed idling rolls 12. In practice, the rolls 12, and all other idling rolls hereafter mentioned, may be grooved about their periphery to insure that the flat wire remains properly positioned between them. After leaving the first pair of opposed rolls 12, the leading end of the fiat wire 10 is then directed to and passed between a second pair of similar opposed idling rolls 13 which are aligned with and spaced from the first pair.

When the leading end of the flat wire 10 is gripped between and protrudes from the second pair of opposed rolls 13, these rolls are revolved in the direction shown by the arrows in FIG. 2 by means of some suitable frame 14 upon which they are rotatably mounted. The number of such revolutions of the pair of opposed rolls 13 on the frame 14 is suicient to twist a section 10A of the at wire 10 between the pairs of rolls 12 and 13 as shown in the drawing. The twisted configuration thereby imparted to the section 10A of the fiat wire consists of a number of helices, each typically about two and one-half inches long for this illustrative wire. This results in plastic deformation of the flat wire 10 in its section 10A so that if its leading end were released it would for-m a succession of helical twists each about six inches long. It is characteristic of this twisted configuration that it is formed about an axis coincident with the center line of the at wire so that the faces of the flat wire define helical surfaces. Such a twisted shape is to be distinguished from the helix of a flat-wire spring which is formed about an axis not coincident with any line in the wire and in which the faces of the wire define cylindrical, and not helical, surfaces.

After the resiliently permanent helical twist has been put to the section 10A of the flat wire in this manner by revolving the second pair of opposed rolls 13, the frame 14 supporting those rolls is secured against further revolution. The leading end of the iat wire is then pulled from the pair of opposed rolls 13 under considerable tension and is connected to the circumference of a driven rotatable non-revolvable collapsible core 15 spaced from the pair of rolls 13. The tension under which the flat wire 10 is thus pulled to the core 15 restrains it from returning fully to its resiliently permanent twisted conliguration imparted by the plastic deformation in the section 10A of the flat wire. Consequently, the tiat wire tends to snap into its helical shape (of six inch pitch helices in this example) between the pair of opposed rolls 13 and the core 15 but it is prevented from doing so. The core 15 is then continuously driven to Wrap the flat wire 10 helically about its circumference. Suitable indexing means are provided to direct the flat wire 10 back and forth along the length of the core 15 to for-m a multi-layered cylindrical winding with a plurality of helical side-by-side turns' in each layer in face-to-face engagement with the turns in the adjoining layers.

Considerable advantage is to be gained from locating the core 15 with respect to the opposed pair of rolls 13 such that the tensioned withdrawn ilat wire engages the circumference of the core (and eventually the circumference of the winding) substantially at a point along the at wire removed from the pair of rolls 13 where the lateral cross section of the tensioned flat wire assumes an orientation substantially parallel to the axis of the core without further applied forces. It will be understood that no matter how forcefully the flat wire 10 is pulled from the opposed pair 13 of rolls, its resiliently permanent twist will still tend to turn some of its increments of length about its center line. Depending upon the wrapping tension and the forcefulness of the tendency of the strip to return to its twisted shape, the at wire 10 will naturally attempt to assume a helical twist of a pitch considerably longer than the exemplary six inch pitch which it would otherwise assume if its outer end were entirely free. We have discovered that if the core 15 is positioned with respect to the rolls 13 so that the iiat wire first engages the circumference of the core (or winding) tangentially at a point along the at wire where its lateral cross section naturally assumes an orientation parallel to the core axis, the at wire will initially lay down in face-to-face engagement with the core (or winding) as it begins each new convolution without being forcibly curled down into such engagement. This avoids any loss of elastic memory which would otherwise occur if the increment of the at wire 10 at iirst tangential engagement with the core (or winding) tended to twist up at that point. The ultimate benefit of this selected positioning of the core 15 is that the throwing force on the flat wire from the package is at a maximum when put in use.

To better insure that the tensioned withdrawn flat wire 10 will engage the circumference of the core or winding at this particular point, one half of a long twist (of 180) is permitted in the hat wire 10 between the pair of opposed rolls 13 and the point of contact with the core 15 (or winding). If more than one such half twist is provided, the core should be moved away from the pair 13 of opposed rolls to a point where the twist ends at 360 (or 540, or 720, etc.), or if no such twist is provided the core 15 should be moved immediately adjacent the pair of opposed rolls 13.

After the desired number of layers are developed in the helical winding about the core 15 to form a package 17, the trailing end of the at wire 10 is anchored to the winding or an outer wrapping is applied about the package, and the package is removed from its driving apparatus. This anchorage of the trailing end of the tlat wire 10 or the provision of an outer wrapping constitutes outer containing means for holding the winding in its cylindrical form around the core 15 and'containing the stored elastic energy in the iiat wire. Another advantage of the new tiat wire package over round wire is that the layers in the former do not always require end-containment by means of flanges on the collapsible core. Layers of round wire do, however, because they could otherwise loosen if their uncontained end convolutions slipped out of the body of the coil.

When the new package 17 is to be used, it is held With its axis pointing in the desired direction of discharge. The core is then collapsed to remove the inner containing forced on the inside circumference of the winding. When this is done, what had been the leading end of the at wire 10 forcibly and instantaneously snaps itself into its inherent exemplary six inch twist, and this release of stored energy discharges that leading end outwardly in the direction of the packages axis. As a result, additional convolutions of the at wire 10 ily from the inside of the package and each progressively rotates into its twisted form. In this process, the etect of the release energy in the progressively lengthening discharged flat wire is cumulative and it throws the already twisted discharged portion even further from the package in the direction of the packages axis. All this occurs with extreme rapidity and with considerable force so that the package disgorges its full length of the wire 10 very quickly at speeds typically about forty miles per hour through a distance of about eighty feet or more.

Typical discharge of flat wire from a package 18 formed in accordance with the invention is shown in FIG. 3. The at wire arches through the air, much like a stream of water from a nozzle, until its progress is interrupted or its full length is expended. If such interruption occurs well within the maximum range of the device, the liat wire will pile up to form an entanglement as shown at 19.

Referring now to FIG. 4, another sequence of steps is illustrated for carrying out the new method. In this embodiment, a flat wire 20 is in the as-rolled condition when it is directed initially between a iirst pair of opposed idling rolls 21. The flat wire 20 is then passed through a high-frequency induction heating coil 22, then through a continuous oil-quenching station 23, and next to a second pair of opposed idling rolls 24 which are revolvable on a frame 25. After leaving the second pair of rolls 24, the wire 20 is passed through a tube furnace 26 and then enters between a third pair of opposed idling rolls 27 mounted on a revolvable frame 28.

Before the continuous process starts, the second pair of rolls 24 is revolved a suicient number of turns to impart the desired over-twist in a section 20A of the flat wire between the first and second pairs of rolls 21 and 24, as described with reference to the FIG. 1 embodiment. Then (or at the same time) the third pair of opposed rolls 27 are revolved twice as many times as the second pair of rolls 24, so that an identical twist is imparted to a section 20B of the wire between the second and third pairs of rolls 24 and 27. This imparts a longitudinally twisted conliguration of equal pitch and direction in the two sections 20A and 20B of the flat wire 20 between the three pairs of rolls. The frames 25 and 28 are then locked to hold that twist, and the leading end of the wire 20 is directed and attached to the circumference of a core 29 spaced from the third pair of opposed rolls 27.

Again, the position of the core 29 with respect to the opposed pair of rolls 27 is such that the withdrawn at wire is engaged with the circumference of the core 29 (or the winding thereon) at a point where the lateral cross-section of the tensioned flat wire 20 assumes an orientation substantially parallel to the axis of the core 29 without further applied forces. The resulting advantages are precisely the same as those achieved by the above-described positioning of the core in the FIG. 1 embodiment. Also, a half twist (of may be permitted between the opposed pair of rolls 27 and this particular point of engagement with the core 29 (or the winding thereon).

As the core 29 is driven, it pulls the at wire 20 through the successive stages of the FIG. 4 method. Thus, the at wire is initially twisted in the section 20A, and in that section it is heated above its critical temperature by means of the induction coil 22. Then this heated twisted portion is subjected to oil-quenching at the station 23 still within the section 20A. This produces a brittle and hard as quenched material which is tempered when it passes through the tube furnace 26 in the next section 20B, and as a consequence, the twisted configuration of the at wire 20 is rendered resiliently permanent. Thus, when it is wrapped at about the core 29 to form a package 30, it is possessed of considerable stored energy tending forcibly to produce a longitudinal twist in the flat wire about an axis coincident with its center line so that the faces of the wire define helical surfaces.

This FIG. 4 embodiment of the method has the advantage of being fully self-contained so that it can be carried out immediately at the outlet end of a rolling mill where flat sheet is cut to width and perhaps serrated along one edge. The operation and eiect of the package 30 are identical to those of the package described with reference to FIG. 2. Y

It is fully contemplated, of course, that many variations can be made in these particular embodiments without parting from the scope of the invention. For example, it is possible, though not entirely practical, to revolve the first pair of rolls 12 in the FIG. 2 embodiment rather than the second opposed pair 13 as described; this applies equally to the FIG. 4 embodiment. Also, additional revolvable pairs of rolls may be included, and they may impart a progressively tighter twist to the at wire rather than the equal twist in the successive sections described in reference to FIG. 4.

Turning now to FIGS. to 9, other forms of the newv package are shown wherein elements such as pointed prongs can project outwardly from the face, as opposed to the edges as in FIG. 1 of the wire after it has been discharged in the manner described. FIG. 5 schematically illustrates the basic method of making these embodiments of the package, and since it is identical to the FIG. 2 method except for the form of the at Wire its characteristic'steps and means for eifecting them will be described only briey. (It will further be evident that the FIG. 4 method is applicable to the fabrication of these FIGS. 5 to 9 embodiments.)

Indenite lengths of a rst strip 3-1 and a second strip 32 are drawn from respective supply sources (not shown in FIG. 5) and superimposed one over the other between a first pair of idling rolls 33. Each strip may be of highcarbon spring steel in a quenched and tempered condition. When the strips 31 and 32 are superimposed between the rolls 33, they form in effect a flat wire 35 'of laminated construction which is then directed to a second pair of similar opposed idling rolls 36. The rolls 36 are revolved on a frame 37 to twist a section 35A of the laminated ilat .wire 35 between theV pairs of rolls 33 and 36. This plastically deforms the section 35A of the laminated at wire as described in reference to FIG. 2. Thereafter, the frame 37 is secured against further revolution and the lead endV of the laminated fiat wire 35 is pulled under considerable tension to a rotatable core 39. Indexing means are provided to direct the at wire 35 along the core 39 to form a multilayered cylindrical winding with a plurality of helical side-by-side turns in each layer in face-to-face engagement with the turns in the adjoining layers. The core 39 may be located with respect to the second pair of idling rolls 36 and 37, and the length of the laminated at wire 35 may undergo a half-turn, as described in reference to FIG. 2. The helical winding developed about the core 39 forms a package 40 which can be released to discharge the laminated at wire 35 outwardly under the cumulative effect of its own released energy, all in the manner described in regard to the package 17 of FIG. 2 except for certain additional features described below.

As shown in FIG. 5, the iirst and second strips 3-1 and 32 which make up the laminated iat wire 35 include a plurality of elements 42 spaced longitudinally along the center line of each strip. One form of these elements is shown in FIG. 6 and it comprises a small piece of highcarbon spring steel cut from at sheet with two pointed portions 43 extending in opposite directions longitudinally with respect to its respective strip, for example the strip 32. In the unrestrained condition of the element 42 show-n in FIG. 6, the pointed portions 43 extend outwardly from the face of the strip 32 at an appreciable angle so that the points are in a markedly exposed position. The element 42 is attached to the strip 32 by a pair of spot welds 44 in its central portion between the pointed portions 43. A plurality of these elements 42 may be welded to each of the strips 31 and 32.

When the strips 31 and 32 are superimposed together between the iirst pair of idling rolls 32 and 33 to form the laminated iiat Wire 35, the elements 42 on the respective strips 31 and 32 assume alternately spaced positions between the strips and their pointed portions 43 are resiliently flattened, as shown in FIG. 7 (which, for clarity, indicates the strips and interposed elements to be thicker than they would be in practice). Thus, in the FIG. 7 condition the iirst and second strips 31 and 32 are separably superimposed compressively together and the resiliently attened pointed portions 43 of each element 42 tend to spring outwardly toward the opposite strip. The at wire 35 remains in this laminated condition shown in FIG. 7 throughout the twisting operation in its section 35A and its winding operation about the core 39. When the core 39 is collapsed and the flat wire 35 hurls itself outwardly u-nder the cumulative impulse of its own released energy as described in reference to the previous embodiments, the first and second strips 31 and 32 separate to allow the pointed portions 43 of the elements 42 to spring outwardly into the angularly projecting position shown in FIG. 6. As a result, the new package of selfdischargeable wire can be used to lay a very eiective barbed entanglement.

Some variations which mayybe made in the FIGS. 5 to 7 embodiment are show-n in FIGS. 8 and 9. In FIG. 8, a strip 46, which may serve as one of the strips constituting the laminated flat wire 35, is partly cut out at 47 so that pointed portions 49 may constitute the pointed elements.

These pointed portions 49 are resiliently flattened during winding in the same manner as the pointed portions 43 of the elements 42, but they differ principally in that they lie within the pla-ne of their strip 46 when resiliently flattened. Thus, the laminated ilat wire which two of these strips 46 form is thinner than that shown in FIG. 7 to the extent that the pointed portions 49 and 50 do not occupy space between the strips.

In FIG. 9, a strip 52 is shown equipped with a welded element 53 similar to the element 42 of FIG. 6 except that a plurality of hook-like barbs 54 are formed along each edge of the resilient pointed portions. These barbs 54, which may also be formed on the pointed portions 49 and 50 in the FIG. 8 embodiment, increase the snagging ability of an entanglement laid down by the package. The snagging eiect may be further increased by including sidewardly-extending barbs along the edges of any one of the strips 31, 32, 46 or 52 in the manner described in reference to FIG. l. Also, more than two of any of these strips may be superimposed one over the other in forming a laminated at wire, so that when the several strips separate during discharge an increasingly greater number of pointed portions or barbs are present in the resulting entanglement. When more than two strips are superimposed in this manner the inner strips of the lamination may have pointed elements extending from both faces thereof.

In all of these forms shown in FIGS. 5 to 9, the laminated at wire 35 made up of the superimposed strips has an ordinary smooth outer surface while it is being twisted in the section 35A and after it is helically wrapped in the winding 40. Therefore, for purposes of forming and operating the self-dischargeable package of FIGS. to 9, it is substantially identical in all respects to the embodiments of FIGS. 1 to 4, both as to its advantages and its variations. It is the barbed entangling effect of the FIGS. 5 to 9 embodiments which differ from that previously discussed, and this advantage results from the laminated form of the flat wire which compresses the resilient elements between its respective strips.

Referring now to FIG. 10, a modified sequence of steps is schematically illustrated which avoids a certain effect in the froegoing forms of the method where two strips are brought together into a laminated fiat wire. In the FIG. 5 method, it happens in some instances that the strip 32 on the inside of the turns in the package 40 tends to buckle because the compressive forces applied to it cannot be relieved by any sliding action between the strips 31 and 32. Such sliding is inhibited because the two strips 31 and 32 forming the fiat wire tend to spring together, not separately, into a helical configuration.

The compression on the inner strip 32 in each convolution of the winding results from the fact that the neutral bending axis of the fiat wire formed by the two strips is at the interface of the two strips. FIG. shows how this can be avoided by subjecting each of two fiat strips 60 and 61 separately to the kind of treatment described in connection with FIGS. 2, 4 or 5. Thus, for example, the -strip 60 is passed between a first pair of opposed rolls 62 and then through a second pair of opposed rolls 63 which may be revolved by a ring 64. When the second pair of rolls 63 is revolved, the characteristic resiliently permanent twisted configuration is imparted to the section 60A of the strip 60 between the pairs of rolls 62 and `63. As this is being done, the other strip 61 is passed in a similar manner between first and second pairs of rolls 66 and l67 respectively, the latter of which can be revolved by a ring 68 to create an intermediate twisted action 61A in the strip.

After the strips 60 and `61 are withdrawn forcibly from their respective second pairs of rolls '63 and 67, they are -both restrained from returning fully to their resiliently permanent shape. At the same time, they are brought together in a superimposed relation to form a laminated fiat wire which is helically wrapped under applied tension about a rotatable non-revolvable core 70 to form a multilayered winding 71. In the winding 71, the strips 60 and 61 forming the fiat wire do not tend to snap into the same helical shape together, but rather they tend to return separately to their own respective helical configurations. Thus, the inner strip 61 in the winding 71 is capable of sliding against the strip 60 that small amount required to relieve compression which could otherwise buckle the inner strip 61.

The method and product of FIG. l0 is open to all the features described hereinbefore except that each strip is separately worked upon up to winding about the core 70, and hence each strip tends to assume a helical twist about its own axis extending therewithin rather than about a single axis common to the laminated fiat wire formed by the strips. With these exceptions which eliminate buckling of the inner strip in the winding turns, the FIG. 10 embodiment may be associated with any of the features described previously with reference to FIGS. 1 through 9.

We claim:

1. A method of making a package of self-dischargeable wire comprising:

(a) 1passing a fiat Wire between a first pair of opposed ro s,

(b) passing said fiat wire between at least one other pair of opposed rolls spaced from said first pair,

(c) imparting a longitudinally twisted configuration to the section of the fiat wire between the pairs of rolls about an axis extending within the fiat wire so that the faces of the fiat wire define helical surfaces,

(d) rendering resiliently permanent the twisted configuration in the section of the fiat wire between the pairs of rolls,

(e) withdrawing said fiat wire forcibly from said other pair of rolls at a fixed rotative orientation relative to its twisted configuration,

(f) restraining said fiat wire after being withdrawn from said other pair of rolls from returning fully to its resiliently permanent twisted configuration, and

(g) helically wrapping said withdrawn fiat wire under applied tension about a rotatable nonrevolvable core to form a multilayered cylindrical winding with a plurality of helical turns in each layer.

2. A method of making a package of self-dischargeable wire which comprises:

(a) passing a fiat steel wire between a first pair of opposed rolls,

(b) passing said flat wire between at least one other pair of opposed rolls spaced from said first pair,

(c) revolving said yother pair of opposed rolls a predetermined number of revolutions, thereby imparting a longitudinally twisted configuration to the section of the fiat wire between the pairs of rolls about an axis extending within the wire so that the faces of the fiat wire define helical surfaces,

(d) securing said revolved other pair of opposed rolls against further revolution,

(e) continuously rendering resiliently permanent the twisted configuration in the section of the fiat wire between the two pairs of rolls,

(f) continuously withdrawing said fiat wire under tension from said other pair of rolls at a fixed rotative orientation relative to its twisted configuration,

(g) restraining said fiat wire after being withdrawn from said other pair of rolls from returning fully to its resiliently permanent twisted configuration, and

(h) continuously helically wrapping said withdrawn fiat wire under applied tension about a rotatable nonrevolvable collapsible core to fosm a multilayered cylindrical winding with a plurality of helical side-byside turns in each layer in face-to-face engagement with the turns in the adjoining layers.

3. A method of making a package of self-dischargeable wire which comprises:

(a) vpassing a fiat steel wire between a first pair of opposed rolls,

(b) passing said fiat wire between at least one other pair of opposed rolls spaced from said first pair,

(c) revolving said other pair of opposed rolls a predetermined number of revolutions, thereby imparting a longitudinally twisted configuration to the section of the at wire between the pairs of rolls about an axis coincident with the center line of the fiat wire so that the faces of the flat wire define helical surfaces,

(d) securing said revolved other pair of opposed rolls against further revolution,

(e) continuously rendering resiliently permanent the twisted configuration in the section of the fiat wire between the two pairs of rolls,

(f) continuously withdrawing said fiat wire under tension from said other pair of rolls while restraining it from returning fully to its resiliently permanent twisted configuration,

(g) engaging the tensioned withdrawn fiat wire with the circumference of a rotatable nonrevolvable collapsible core substantially at a point removed from said other pair of rolls where the lateral cross-section of the tensioned fiat wire assumes an orientation substantially parallel to the axis of the core without further applied forces, and

(h) continuously helically wrapping said Withdrawn fiat wire under applied tension about said core to form a mutilayered cylindrical winding with a plurality of helical side-by-side turns in each layer in faceto-face engagement with the turns in the adjoining layers.

4. A method of making a package of selfdischargeable wire which comprises:

(a) passing a fiat wire between a first pair of opposed rolls,

(b) passing said fiat wire between a second pair opposed rolls spaced from said first pair,

(c) revolving one of said pairs of opposed rolls a predetermined number of revolutions with respect to the other pair, thereby plastically deforming a longitudinally twisted resilient configuration in the section of the at wire between the pairs of rolls about an axis extending within the fiat wire so that the faces of the wire define helical surfaces,

- (d) securing said revolved pair of opposed rolls against further revolution,

(e) withdrawing said wire forcible from said second pair of rolls at a fixed rotative orientation relative to its twisted configuration,

(f) restraining said fiat wire after being withdrawn from said other pair of rolls from returning fully to its resiliently permanent twisted configuration, and

(g) helically wrapping said withdrawn fiat wire under applied tension about a rotatable nonrevolvable core to form a multilayered cylindrical winding with a plurality of helical turns in each layer.

5. A method of making a package of self-dischargeable Wire which comprises:

(a) passing a fiat wire between a first pair of opposed rolls, (b) passing said flat wire between a second pair of opposed rolls spaced from said first pair, (c) revolving said second pair of opposed rolls a predetermined number of revolutions, thereby imparting a plastically deformed longitudinally twisted resilient configuration to the section of the flat wire between the two pairs of rolls about an axis extending within the flat wire so that the faces of the flat wire define helical surfaces, (d) securing said revolved second pair of opposed rolls against further revolution,

(e) withdrawing said fiat wire under tension from said second pair of rolls while restraining it from returning fully to its resiliently permanent twisted configuration,

(f) engaging the tensioned withdrawn flat wire with the circumference of a rotatable nonrevolvable collapsible core Isubstantially at a point removed from said second pair of rolls where the lateral cross-section of the tensioned fiat wire assumes an orientation substantially parallel to the axis of the core without further applied forces, and

(g) helically wrapping said withdrawn fiat wire under applied tension about said core to form amultilayered cylindrical winding with a plurality of helical turns in each layer in face-toface engagement with the turns in the adjoining layers.

6. A method of making a package of self-dischargeabl wire which comprises: Y

(a) passing a quenched and tempered fiat steel wire between a first pair of opposed rolls,

(b) passing said fiat wire between a second pair of opposed rolls spaced from said first pair,

(c) revolving said second pair of opposed rolls a predetermined number of revolutions, thereby imparting a plastically deformed longitudinally twisted resilient configuration to the section of the flat wire between the two pairs of rolls about an axis coincident with the center line of the flat wire so that the faces of the fiat wire define helical surfaces,

(d) securing said revolved second pair of opposed rolls against further revolution,

(e) continuously withdrawing said flat wire under tension from said second pair of rolls while restraining it from returning fully to its resiliently permanent twisted configuration,

(f) engaging the tensioned withdrawn wire with the circumference of a rotatable non-revolvable collapsible core substantially at a point removed from said second pair of rolls where the lateral cross-section of the tensioned flat wire assumes an orientation substantially parallel to the axis of the core without further applied forces, and

(g) continuously helically wrapping said withdrawn fiat wire under applied tension about said core to form a multilayered cylindrical winding with a plurality of helical side-by-side turns in each layer in face-to-face engagement with the turns in the adjoining layers.

7. A method of making a package of self-dischargeable wire which comprises:

(a) passing a flat metal wire between a first pair of opposed rolls,

(b) passing said fiat wire between at least one other pair of opposed rolls spaced from said first pair,

(c) revolving one of said pairs of opposed rolls a predetermined number of revolutions with respect to the first pair, thereby imparting a longitudinally twisted resilient configuration to the section of the flat wire `between the pairs of rolls about an axis extendingA within the fiat wire so that the faces of the flat wire define helical surfaces,

(d) securing said revolved pair of opposed rolls against further revolution,

(e) heating said twisted section of said flat wire to a temperature above its critical point,

(f) quenching said heated section of said fiat wire,

(g) tempering said quenched section of said fiat wire, thereby rendering resiliently permanent the twisted configuration in the section of the fiat wire between the pairs of rolls,

(h) withdrawing said fiat wire forcibly from said other pair of rolls at a fixed rotative orientation relative to its twisted configuration,

(i) restraining said flat wire after being withdrawn from said other pair of rolls from returning fully to its resiliently permanent twisted configuration, and

(j) helically wrapping said withdrawn fiat wire under applied tension about a rotatable nonrevolvable core to form a multilayered cylindrical winding with a plurality of helical turns in each layer.

8. A method of making a package of self-dischargeable wire which comprises:

(a) passing a fiat steel wire between a first pair of opposed rolls, Y

(b) passing said fiat wire between at least one other pair of opposed rolls spaced from said first pair,

(c) revolving said other pair of opposed rolls a predetermined number of revolutions, thereby imparting a longitudinally twisted resilient configuration to the section of the fiat wire between the pairs of rolls about an axis extending within the flat wire so that the faces of the fiat wire define helical surfaces,

(d) securing said revolved pair of opposed rolls against further revolution,

(e) continuously heating by means of an induction coil said twisted section of said at wire between the pairs of rolls to a temperature above its critical point,

(f) continuously oil-quenching said heated `section of said fiat wire between the pairs of rolls,

(g) continuously tempering said quenched section of said at wire between the pairs of rolls, thereby rendering resiliently permanent the twisted configuration in the flat wire,

(h) continuously withdrawing said fiat wire under tension from said other pair of rolls while restraining it from returning fully to its resiliently permanent twisted configuration,

(i) engaging the tensioned withdrawn fiat wire with the circumference of a rotatable.- non-revolvable collapsible core substantially at a point removed from said other pair of rolls where the lateral cross-section 9. A method of making a package of self-dischargeable I Wire which comprises:

(a) passing a at steel wire between three successive spaced pairs of opposed rolls,

(b) revolving the latter two of the successive pairs of opposed rolls a predetermined number of revolutions, thereby imparting a longitudinally twisted resilient configuration of equal pitch and direction to the two sections of the fiat wire between the three pairs of rolls about an axis coincident with the center line of the flat wire so that the faces of the at wire define helical surfaces,

(c) securing said two revolved pairs of opposed rolls against further revolution,

(d) continuously heating by means of an induction coil said twisted section of said flat wire between the rst and second pairs of rolls to a temperature above its critical point,

(e) continuously oil-quenching said heated section of said at Wire between the first and second pairs of rolls,

(f) continuously tempering said quenched section of said at wire between the second and third pairs of rolls, thereby rendering resiliently permanent the twisted configuration in the at wire,

(g) continuously withdrawing said dat wire under tension from said third pair of rolls while restraining it from returning fully to its resiliently permanent twisted configuration,

(h) engaging the tensioned withdrawn fiat wire rwith the circumference of a rotatable nonrevolvable collapsible core substantially at a point removed from said third pair of rolls Where the lateral cross-section of the tensioned fiat wire assumes an orientation substantially parallel to the axis of the core without further applied forces, and

(i) continuously helically wrapping said withdrawn flat wire under applied tension about said core to form a multilayered cylindrical winding with a plurality of helical side-by-side turns in each layer in face-to-face engagement with the turns in the adjoining layers.

10. A method of making a package of self-dischargeable wire comprising:

(a) subjecting each of at least two fiat strips separately to the following steps:

(i) plassing the strip between a first pair of opposed rol s,

(ii) passing the strip between at least one other pair of opposed rolls spaced from said first Pall',

(iii) revolving said other pair of opposed rolls a predetermined number of revolutions with respect to said first pair, thereby imparting a longitudinally twisted configuration to the section of the strip between the pairs of rolls about an axis extending within the strip so that the faces of the strip define helcal surfaces,

(iv) securing said revolved pair of opposed rolls against further revolution,

|(v) rendering resiliently permanent the twisted configuration in the section of the strip between the pairs of rolls, and

(vi) withdrawing the strip forcibly from said other pair of rolls at a fixed rotative orientation relative to its twisted configuration,

(b) restraining said flat wire after being withdrawn from said other pair of rolls from returning fully to its resiliently permanent twisted configuration;

(c) superimposing each of the strips together to form va laminated flat wire; and

(d) helically wrapping the flat wire under applied tension about a rotatably nonrevolvable core to form a multi-layered cylindrical winding with a plurality of helical turns in each layer.

11. A method of making a package of self-dischargeable wire comprising:

(a) subjecting each of at least two fiat strips separately to the following steps:

(i) passing the strip between a first pair of opposed rolls,

(ii) passing the strip between a second pair of opposed rolls spaced from said first pair,

(iii) revolving one of said pairs of opposed rolls a predetermined number of revolutions with respect to the other pair, thereby plastically deforming a longitudinally twisted resilient configuration in the section of the strip between the pairs or rolls about an axis extending within the strip so that the faces of the strip define helical surfaces,

(iv) securing said revolved pair of opposed rolls against further revolution, and

(v) withdrawing the strip forcibly from said second pair of rolls at a fixed rotative orientation relative to its twisted configuration,

(b) restraining said at wire after being withdrawn from said other pair of rolls from returning fully to its resiliently permanent twisted configuration,

(c) superimposing each of the strips together to form a laminated at wire; and

(d) helically wrapping the flat wire under applied tension 1 about a rotatable non-revolvable core to for a multilayered cylindrical winding with a plurality of turns in each layer.

12. A method of making a package of self-dischargeable wire which comprises:

(a) subjecting each of at least two at steel strips separately to the following steps:

(i) plassing the strip between a first pair of opposed rol s,

(ii) passing the strip between at least one other pair of opposed rolls spaced from said first pair,

(iii) revolving said other pair of opposed rolls a predetermined number of revolutions, thereby imparting a longitudinally twisted resilient configuration to the section of the strip between the pairs of rolls about an axis extending Within the strip so that the faces of the strip define helical surfaces,

(iv) securing said revolved pair of opposed rolls against further revolution,

(v) continuously heating by means of an induction coil said twisted section of the strip between the pairs of rolls to a temperature above its critical point,

l(vi) continuously oil-quenching said heated section of the strip between the pairs of rolls,

(vii) continuously tempering said quenched section of the strip between the pairs of rolls, thereby rendering resiliently permanent the twisted configuraton in the strip, and

(viii) continuously withdrawing the strip under tension from said other pair of rolls while restraining it from returning fully to its resiliently permanent twisted configuration;

(b) compressively superimposing each of the strips together to form a laminated at wire;

(c) engaging the tensioned strips with the circumference of a rotatable non-revolvable collapsible core where they yare superimposed together and substantially at a point removed from said other pair of rolls Referencs 'Cited l where th'latiral cross-section of eali tensioned strip assumes an orientation substantially "parallel to f UNITED STATES P TENTS i llill axls of the core wlthout further'applled forces, l 2,370,036 *Y 2/19-45: Howell: .LLTT--- Ii-A-.v 89-36 (d) continuously lielically Wrapping the flat wire under t l 1 applied tension about said core to'forrn a multi- 5 JOHNPETRAKES Primary Egammel layered cylindrical winding with a plurality of -helical I l v J t u i A U.S. Cl. X.R.v i side-by-slde turns 1n each layer 1n face-to-face eng gagement with the turnsin ih e adjoininglayers.v 57-167; 124-18 

